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Limited Warranty Statement

Stellar Industries, Inc. (Stellar) warrants products designed and manufactured by Stellar to be free from defects in material and workmanship

under proper use and maintenance. Products must be installed and operated in accordance with Stellar’s written instructions and capacities. The

warranty period shall cover the following:

Twelve (12) month warranty on parts from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) months from

date of manufacture,

Twelve (12) month repair labor from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) month from date of

manufacture, and

Thirty-six (36) month warranty on all Stellar Crane, Hooklift Hoist, Cable Hoist, and Container Carrier structural parts from the date recorded by

Stellar as the in-service date, not to extend beyond forty-eight (48) months from date of manufacture.

The in-service date will be derived from the completed warranty registration card. In the event a warranty registration card is not received by

Stellar, the factory ship date will be used. 

Stellar’s obligation under this warranty is limited to, and the sole remedy for any such defect shall be, the repair and/or replacement (at Stellar’s

option) of the unaltered part and/or component in question. Stellar after-sales service personnel must be notified by telephone, fax, or letter of

any warranty-applicable damage within fourteen (14) days of its occurrence. If at all possible, Stellar will ship the replacement part within 24-

hours of notification by the most economical, yet expedient, means possible. Expedited freight delivery will be at the expense of the owner.

Warranty claims must be submitted and shall be processed in accordance with Stellar’s established warranty claim procedure. Stellar after-sales

service personnel must be contacted prior to any warranty claim. A return materials authorization (RMA) account number must be issued to the

claiming party prior to the return of any warranty parts. Parts returned without prior authorization will not be recognized for warranty consideration.

All damaged parts must be returned to Stellar freight prepaid; freight collect returns will be refused. Freight reimbursement of returned parts will

be considered as part of the warranty claim.

Warranty service will be performed by any Stellar new equipment distributor, or by any Stellar-recognized service center authorized to service the

type of product involved, or by the Stellar factory in the event of a direct sale. At the time of requesting warranty service, the owner must present

evidence of date of delivery of the product. The owner shall be obligated to pay for any overtime labor requested of the servicing company by the

owner, any field service call charges, and any towing and/or transportation charges associated with moving the equipment to the designated

repair/service provider.

All obligations of Stellar and its authorized dealers and service providers shall be voided if someone other than an authorized Stellar dealer

provides other than routine maintenance service without prior written approval from Stellar. In the case repair work is performed on a Stellar-

manufactured product, original Stellar parts must be used to keep the warranty in force. The warranty may also be voided if the product is

modified or altered in any way not approved, in writing, by Stellar.

The owner/operator is responsible for furnishing proof of the date of original purchase of the Stellar product in question. Warranty registration is

the ultimate responsibility of the owner and may be accomplished by the completion and return of the Stellar product registration card provided

with the product. If the owner is not sure of registration, he is encouraged to contact Stellar at the address below to confirm registration of the

product in question. This warranty covers only defective material and workmanship. It does not cover depreciation or damage caused by normal

wear and tear, accident, mishap, untrained operators, or improper or unintended use. The owner has the obligation of performing routine care

and maintenance duties as stated in Stellar’s written instructions, recommendations, and specifications. Any damage resulting from

owner/operator failure to perform such duties shall void the coverage of this warranty. The owner will pay the cost of labor and supplies

associated with routine maintenance.

The only remedies the owner has in connection with the breach or performance of any warranty on the Stellar product specified are those set

above. In no event will Stellar, the Stellar distributor/dealer, or any company affiliated with Stellar be liable for business interruptions, costs of

delay, or for any special, indirect, incidental, or consequential costs or damages. Such costs may include, but are not limited to, loss of time, loss

of revenue, loss of use, wages, salaries, commissions, lodging, meals, towing, hydraulic fluid, or any other incidental cost. 

All products purchased by Stellar from outside vendors shall be covered by the warranty offered by that respective manufacturer only. Stellar

does not participate in, or obligate itself to, any such warranty.

Stellar reserves the right to make changes in design or improvement upon its products without imposing upon itself the same upon its products

theretofore manufactured.

This warranty will apply to all Stellar Hooklift Hoists, Stellar Cable Hoists, Stellar Container Carriers, Stellar Service Trucks, Stellar Truck-mounted

Cranes, and Stellar Compactors shipped from Stellar’s factory after March 1, 2008. The warranty is for the use of the original owner only and is

not transferable without prior written permission from Stellar.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR

FITNESS FOR A PARTICULAR PURPOSE. REMEDIES UNDER THIS WARRANTY ARE LIMITED TO THE PROVISION OF MATERIAL AND SERVICES, AS

SPECIFIED HEREIN. STELLAR INDUSTRIES, INC. IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

Revision Date: July 2008

Document Number: 37040

Summary of Contents for Flex36 108-12

Page 1: ...0 321 3741 Fax 641 923 2811 www stellarindustries com Safety Operation Installation Maintenance OWNERS MANUAL FLEX36 HOOKLIFT Manual Part No 35551 Last Revision 01 14 10 Subject to Change without Noti...

Page 2: ...f Revision Updated Reservoir Assembly Drawing PN 35883 to reflect engineering changes Updatted Base Assembly Drawing Drawings to reflect engineering changes Updated Controller Assembly to reflect engi...

Page 3: ...lve All Models PN 37741 24 Reservoir Assembly PN 35883 25 Setting System Relief Pressure 26 Installation Instructions for the Power Beyond VDM8 Valve 28 Port Side Relief Installation 29 Controller Ass...

Page 4: ...Use only factory approved accessories options and parts on this equipment The rebuilding or remounting of this equipment requires the mounting procedures and retesting to be in accordance with factor...

Page 5: ...the unit A few notes on this manual A copy of this manual is provided with every hooklift and shall remain with the hooklift at all times Information contained within this manual does not cover all m...

Page 6: ...ng containers to dump bodies Two independently controlled cylinders operate all the functions of the Stellar Flex By varying the cylinder operation the Stellar Flex can be used to dump or unload a bod...

Page 7: ...fety devices Do not remove any decals Chapter 1 Safety General Safety It is the responsibility of the owner to instruct the operator in the safe operation of your equipment and to provide the operator...

Page 8: ...not attempt to lift fixed loads Know the weight of your load to avoid over loading the equipment Deduct the weight of the body from the maximum load rating to determine how much weight can be lifted...

Page 9: ...be fully extended before operating the lift cylinder to prevent damage to the latch systems 2 When the PTO is engaged do not run the engine over 1400 RPM 3 Do not hold the brakes while performing ope...

Page 10: ...location you wish to unload 2 Put the truck in neutral and engage the PTO Run RPM as needed 3 Locate the black control lever labeled tilt 4 Pull the tilt lever until the cylinder is fully extend ed th...

Page 11: ...needed 3 Locate the black control lever labeled tilt 4 Pull the tilt lever until the cylinder is fully extended thus releasing tabs 5 Locate the red lever labeled lift 6 Pull lift lever until the body...

Page 12: ...body you intent to pick up 2 Engage the hook to the body by maneuvering the hooklift with the red lift lever Run RPM as needed 3 Push the red lift lever until the main cylinder is fully retracted 4 P...

Page 13: ...o dump the load 2 Put the truck in neutral and engage the PTO Run RPM as needed 3 Locate the red lever labeled lift 4 Pull the lift lever to dump the body 5 Wait until dumping is complete then push th...

Page 14: ...8 Flex36 Owner s Manual...

Page 15: ...e first month of operation on new machines and then quarterly thereafter 2 Cylinders and valves for leaks 3 Lubrication 4 Tilt hook for cracks 5 Structural weldments for bends cracks or breaks 6 All p...

Page 16: ...erature Modified Sodium Based High Drop Point Transmission Semi Fluid Calcium Based Molybdenum Filled Lithium Based with 2 Molybdenum Disulfide Graphite Filled Sodium Based with 2 Graphite Block Greas...

Page 17: ...7kg A Dump Angle 54 53 54 50 B Lowest Hook Heigh 23 5 60cm 25 63 5cm 27 68 5cm 28 71cm C Effective Length 91 231cm 115 292cm 142 361cm 151 383 5cm D Truck Frame Height 34 86cm 36 91 5cm 36 91 5cm 36 9...

Page 18: ...revent exposure of cylinder rod to corrosive road salts Tilt Section Operation Hooklift must include a hydraulic lock out device to prevent operation of the tilt section while hooklift is in the dumpi...

Page 19: ...vent exposure of cylinder rod to corrosive road salts Tilt Section Operation Hooklift must include a hydraulic lock out device to prevent operation of the tilt section while hooklift is in the dumpin...

Page 20: ...pre vent exposure of cylinder rod to corrosive road salts Tilt Section Operation Hooklift must include a hydraulic lock out device to prevent operation of the tilt section while hooklift is in the du...

Page 21: ...vent exposure of cylinder rod to corrosive road salts Tilt Section Operation Hooklift must include a hydraulic lock out device to prevent operation of the tilt section while hooklift is in the dumpin...

Page 22: ...16 Flex36 Owner s Manual...

Page 23: ...tilt operation the possible consequences should the haz ard occur and how to avoid the hazard PN C0865 Operation Hazard Decal Location Truck Frame Function To inform the operator of the need for prop...

Page 24: ...18 Flex36 Owner s Manual Decal Kit Placement PN 35559 PN 35559...

Page 25: ...8 Mount hydraulic reservoir tank and valve bank 9 Mount PTO and Pump 10 Run hydraulic hoses 11 Connect suction and pressure to the reservoir tank and valve bank 12 Install mud flaps and fenders 13 Run...

Page 26: ...Place a tie down channel on either side of the base within 2 of the front plate c Place a tie down channel on either side of the base within 7 of the rear of the hooklift d The final channels should...

Page 27: ...TO and valve bank c Protect these lines with hose wrap when necessary d Keep these lines away from sharp edges e Keep these lines away from the exhaust or other temperature extreme items f Keep these...

Page 28: ...N 33320 ITEM PART DESCRIPTION QTY 1 D0143 TIE DOWN CHANNEL 8 2 C1025 CAP SCR 0 63 11X2 00 HHGR8 ZY 8 3 C1038 WASHER 0 63 FLAT 16 4 24868 NUT 0 63 11 HH NYLOC 8 5 D0045 BACKUP ALARM 97 DECIBAL 1 Mounti...

Page 29: ...E N N A H C N W O D E I T 3 4 1 0 D 1 2 1 Y Z 8 R G H H 0 0 2 X 1 1 3 6 0 R C S P A C 5 2 0 1 C 2 4 2 T A L F 3 6 0 R E H S A W 8 3 0 1 C 3 2 1 C O L Y N H H 1 1 3 6 0 T U N 8 6 8 4 2 4 1 L A B I C E...

Page 30: ...PLATE ROTARY VALVE ARM 1 10 0482 CAP SCR 0 25 20 X 3 00 HHGR5 2 11 0333 NUT 0 25 20 HHGR5 NYLOC 2 12 7350 FTG ST RUN TEE 8R5OLO 2 13 D1535 PLUG STR HOLLOW HEX 0 50 8 HP5ON 2 37741 Rotary Valve All Mod...

Page 31: ...X2 50 HHGR5 3 Y T Q N O I T P I R C S E D T R A P M E T I 13 C4227 FTG MF MSTR 90 8 12 C5OLO S 1 14 26731 HOSE 0 50 381 JC J9 8 8 8 18 0 1 15 0352 WASHER 0 50 USS FLAT ZINC 8 16 C6106 NUT 0 50 13 HHGR...

Page 32: ...e next page for details 4500 5500 6500 7500 8500 9500 10500 11500 12500 13500 14500 15500 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000 4200 4400 SYSTEM RELIEF PRESSURE P S I LOADER CAPACITY...

Page 33: ...the system relief pressure using 4 mm allen wrench Clockwise increases pressure counter clock wise decreases pressure 5 Once system pressure is set tighten the jam nut to lock system pressure Permanen...

Page 34: ...power beyond on a Salami VDM8 valve bank If any hydraulic component is integrated after this valve the power beyond must be installed correctly or serious damage may incur to the hydraulic system Ins...

Page 35: ...IDE RELIEF MAIN RELIEF VALVE BANK For some options port side relief is required To install port side relief 1 Remove plug 2 Insert relief 3 Replace plug Relief can be installed on the retract or exten...

Page 36: ...NTROL CABLE 96 IN WESCON 2 3 14 37472 CONTROL CABLE 144 IN WESCON 2 3 14 37473 CONTROL CABLE 192 IN WESCON 2 3 17 20057 CAP SCR 0 31 18X6 50 HHGR5 3 Section Only 2 17 0491 CAP SCR 0 31 18X4 00 HHGR5 2...

Page 37: ...be located directly above dump light switch when secondary is in lowered position Screw in elevator bolt and adjust so that switch is engaged when secondary is in lowered position Install light in br...

Page 38: ...VB TO PORT TUBES C2773 HOSE 50 STELLAR 18169 471TC JC J9 8 8 8 60 60 00 FUNCTION MAIN CYLINDER C1558 QTY 2 C1559 C0562 HOSE 38 91 00 STELLAR 34646 471TC JC J9 8 6 6 91 FUNCTION TILT ROTARY VAVLVE TO...

Page 39: ...TO PORT TUBES C2773 HOSE 50 STELLAR 18169 471TC JC J9 8 8 8 60 60 00 FUNCTION MAIN CYLINDER C1558 QTY 2 C1559 C0562 HOSE 38 115 00 STELLAR 34648 471TC JC J9 8 6 6 115 FUNCTION TILT ROTARY VAVLVE TO CY...

Page 40: ...VB TO PORT TUBES C2773 HOSE 50 STELLAR 18169 HTB JC J9 8 8 8 60 60 00 FUNCTION MAIN CYLINDER C1558 QTY 2 C1559 C0562 HOSE 38 145 00 STELLAR 34649 471TC JC J9 8 6 6 145 FUNCTION TILT ROTARY VAVLVE TO C...

Page 41: ...6392 QTY 2 FUNCTION TILT VB TO PORT TUBES C2773 HOSE 50 STELLAR 18169 471TC JC J9 8 8 8 60 60 00 FUNCTION MAIN CYLINDER C1558 QTY 2 C1559 C0562 HOSE 38 150 00 STELLAR 34650 471TC JC J9 8 6 6 150 FUNC...

Page 42: ...36 Flex36 Owner s Manual multi lift only Subframe Model 60 8...

Page 43: ...Installation 37 Subframe Model 84 10...

Page 44: ...38 Flex36 Owner s Manual Subframe Model 108 12...

Page 45: ...Installation 39 Subframe Model 120 14...

Page 46: ...40 Flex36 Owner s Manual...

Page 47: ...01X3 50X2 88 2 Y T Q N O I T P I R C S E D T R A P M E T I 10 22764 COLLAR 2 01X3 00X1 00 2 11 0507 CAP SCR 0 50 13X4 50 HHGR5 2 12 C6106 NUT 0 50 13 HHGR5 NYLOC 2 13 C0953 CAP SCR 0 38 16X4 00 HHGR5...

Page 48: ...50 13X4 50 HHGR5 2 Y T Q N O I T P I R C S E D T R A P M E T I 10 C6106 NUT 0 50 13 HHGR5 NYLOC 2 11 0532 CAP SCR 0 38 16X3 75 HHGR5 2 2 C O L Y N H H 6 1 8 3 0 T U N 7 4 3 0 2 1 13 C0078 HOSE CLAMP...

Page 49: ...Y T Q N O I T P I R C S E D T R A P M E T I 2 0 0 1 X 0 0 3 X 1 0 2 R A L L O C 4 6 7 2 2 0 1 11 0532 CAP SCR 0 38 16X3 75 HHGR5 2 2 C O L Y N H H 6 1 8 3 0 T U N 7 4 3 0 2 1 13 0507 CAP SCR 0 50 13X4...

Page 50: ...2 9 Y T Q N O I T P I R C S E D T R A P M E T I 10 0532 CAP SCR 0 38 16X3 75 HHGR5 2 2 C O L Y N H H 6 1 8 3 0 T U N 7 4 3 0 1 1 12 C0078 HOSE CLAMP 8 RUBBER COATED 1 13 0479 CAP SCR 0 25 20X0 75 HHGR...

Page 51: ...5 25 1 4 2257 SNAP RING INSIDE 2 00 2 5 33062 TAB LOADER WLDMT BREAK AWAY 1 6 0332 CAP SCR 0 31 18X1 75 HHGR5 2 7 23301 TAB LOADER BREAK AWAY 1 8 0506 CAP SCR 0 50 13X4 00 HHGR5 2 9 0333 NUT 0 25 20 H...

Page 52: ...X25 25 1 4 2257 SNAP RING INSIDE 2 00 2 5 33062 TAB LOADER WLDMT BREAK AWAY 1 6 0332 CAP SCR 0 31 18X1 75 HHGR5 2 7 23301 TAB LOADER BREAK AWAY 1 8 0506 CAP SCR 0 50 13X4 00 HHGR5 2 9 0333 NUT 0 25 20...

Page 53: ...NG 32DXR32 2 00X2 00 GARLOCK 6 8 0332 CAP SCR 0 31 18X1 75 HHGR5 2 3 22227 PIN 2 00X25 25 1 9 0333 NUT 0 25 20 HHGR5 NYLOC 2 4 2257 SNAP RING INSIDE 2 00 2 10 C6106 NUT 0 50 13 HHGR5 NYLOC 2 5 33062 T...

Page 54: ...X25 25 1 4 2257 SNAP RING INSIDE 2 00 2 5 33062 TAB LOADER WLDMT BREAK AWAY 1 6 23301 TAB LOADER BREAK AWAY 1 7 0506 CAP SCR 0 50 13X4 00 HHGR5 2 8 0332 CAP SCR 0 31 18X1 75 HHGR5 2 9 0333 NUT 0 25 20...

Page 55: ...DER ASM 27020 4 00X29 63 1 3 4381 BUSHING 32DXR32 2 00X2 00 GARLOCK 6 4 22286 PIN 2 00X16 00 1 5 2257 SNAP RING INSIDE 2 00 2 6 0068 BUSHING QSI 1618 24 4 7 0069 BUSHING QSI 1618 16 4 8 22285 PIN 1 00...

Page 56: ...USHING 32DXR32 2 00X2 00 GARLOCK 6 3 0069 BUSHING QSI 1618 16 4 4 3875 SNAP RING 1 00 INTERNAL 2 5 22285 PIN 1 00X15 00 1 6 22286 PIN 2 00X16 00 1 7 2257 SNAP RING INSIDE 2 00 2 8 0068 BUSHING QSI 161...

Page 57: ...HING 32DXR32 2 00X2 00 GARLOCK 6 3 0068 BUSHING QSI 1618 24 4 4 0069 BUSHING QSI 1618 16 4 5 3875 SNAP RING 1 00 INTERNAL 2 6 22285 PIN 1 00X15 00 1 7 22286 PIN 2 00X16 00 1 8 2257 SNAP RING INSIDE 2...

Page 58: ...USHING 32DXR32 2 00X2 00 GARLOCK 6 3 0068 BUSHING QSI 1618 24 4 4 0069 BUSHING QSI 1618 16 4 5 3875 SNAP RING 1 00 INTERNAL 2 6 22285 PIN 1 00X15 00 1 7 22286 PIN 2 00X16 00 1 8 2257 SNAP RING INSIDE...

Page 59: ...60 CYLINDER ASM 3 00X17 00 1 8 D0419 THRUST WASHER 2 3 0069 BUSHING QSI 1618 16 1 9 33104 COLLAR 1 03X2 00X1 00 2 4 0064 PIN 1 00X3 38 1 10 0339 CAP SCR 0 25 20X2 50 HHGR5 2 5 0110 SNAP RING 1 00 ID 7...

Page 60: ...SHER 2 7 33104 COLLAR 1 03X2 00X1 00 2 8 0339 CAP SCR 0 25 20X2 50 HHGR5 2 9 0333 NUT 0 25 20 HHGR5 NYLOC 2 10 c1592 ZERK 1 8 NPT STRAIGHT 4 11 35066 PIN 1 00X18 38 SR 1 12 0867 MACHY WASHER 1 00ID 14...

Page 61: ...ART DESCRIPTION QTY 1 3767 CYLINDER 3 00X17 00 1 2 0279 FTG ADAPT 6 F5OLO S 2 3 0068 BUSHING QSI 1618 24 2 Bushing shown as reference Tilt Cylinder Assembly All Flex36 Models PN 23460 Note This Tilt C...

Page 62: ...SHING 32DXR32 2 00X2 00 GARLOCK 4 3 15822 MANIFOLD DOUBLE T11A 5000 PSI 1 4 27117 TUBE ASM 0 50X11 94 2 5 19369 HOSE CLAMP 4 13 7 00 5416K38 2 6 18701 CLAMP PORT TUBE ZR518 2 7 D1290 FTG ADAPT 8 6 F5O...

Page 63: ...A G T F 9 7 2 0 2 3 D1290 FTG ADAPT 8 6 F5OLO S 5 4 15822 MANIFOLD DOUBLE T11A 5000 PSI 1 5 4381 BUSHING 32DXR32 2 00X2 00 GARLOCK 4 1 5 7 7 2 X 0 5 0 M S A E B U T 4 4 7 3 3 6 7 19369 HOSE CLAMP 4 13...

Page 64: ...T F 9 7 2 0 2 3 D1290 FTG ADAPT 8 6 F5OLO S 5 4 15822 MANIFOLD DOUBLE T11A 5000 PSI 1 5 4381 BUSHING 32DXR32 2 00X2 00 GARLOCK 4 1 3 1 0 4 X 0 5 0 M S A E B U T 0 5 7 3 3 6 7 19369 HOSE CLAMP 4 13 7 0...

Page 65: ...16 Cable Hook up Kit Snap Ring 2 00 External Snap Ring 2 00 Internal Snap Ring 1 00 Internal Grease Zerk 1 8 NPT Tab Alarm Proximity Switch Bosch Relay Seal Kit Rotary Valve Seal Kit Tilt Cyl Seal Ki...

Page 66: ...60 Flex36 Owner s Manual...

Page 67: ...hanged per the maintenance page of the Hooklift Owner s Manual Make sure the filter strainer of the hydraulic reser voir is not plugged Make sure that the hydraulic pump is operating at its rated flow...

Page 68: ...rized dealers and service providers shall be voided if someone other than an authorized Stellar dealer provides other than routine maintenance service without prior written approval from Stellar In th...

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